2002 YAMAHA MAJESTY 250 Cowling B

PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ......................................................6-1
Periodic maintenance and lubrication chart ..........6-3
Removing and installing the cowlings and panel ...6-6
Checking the spark plug ......................................6-12
Engine oil .............................................................6-14
Final transmission oil ...........................................6-18
Coolant ................................................................6-19
Air filter and V-belt case air filter elements ..........6-21
Air flow louver ......................................................6-23
Adjusting the throttle cable free play ...................6-23
Adjusting the valve clearance ..............................6-23
Tires ....................................................................6-24
Cast wheels .........................................................6-26
Adjusting the front and rear brake lever
free play .............................................................6-27
Checking the front and rear brake pads ..............6-28
Checking the brake fluid level .............................6-29
Changing the brake fluid .....................................6-30
Checking and lubricating the cables ....................6-30
Checking and lubricating the throttle grip
and cable ...........................................................6-31
Lubricating the front and rear brake levers ..........6-31
Checking and lubricating the centerstand
and sidestand ....................................................6-31Checking the front fork ........................................6-32
Checking the steering ..........................................6-33
Checking the wheel bearings ..............................6-33
Removing the battery cover ................................6-34
Battery .................................................................6-34
Replacing the fuses .............................................6-36
Replacing a headlight bulb ..................................6-37
Replacing a front turn signal light bulb ................6-39
Replacing a rear turn signal light bulb .................6-40
Replacing a tail/brake light bulb ..........................6-40
Replacing the license plate light bulb ..................6-41
Troubleshooting ...................................................6-42
Troubleshooting charts ........................................6-43
6
5SJ-28199-E0 1/24/02 6:14 PM Page 49

6-6
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03624
Removing and installing the
cowlings and panelCowlings and panel, removing and installingThe cowlings and panel shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section
each time a cowling or the panel
needs to be removed and installed.
1
1. Cowling A
1
1. Cowling C
1
1. Cowling B
5SJ-28199-E0 1/24/02 6:14 PM Page 55

6-7
PERIODIC MAINTENANCE AND MINOR REPAIR
6
1
1. Panel A
2. Remove the cowling screws.
2 11
1. Screw (×4)
2. Cowling A
EAU03615
Cowling A
To remove the cowling1. Pull up the left floorboard mats
as shown.
1
2
1. Mat A
2. Mat B
5SJ-28199-E0 1/24/02 6:14 PM Page 56

6-8
PERIODIC MAINTENANCE AND MINOR REPAIR
6 3. Pull the cowling down slightly,
and then pull it outward as
shown.
EAU03632
Cowling B
To remove the cowling1. Pull up the right floorboard mats
as shown.
1
2
1. Mat A
2. Mat B
To install the cowling1. Insert the tabs on the cowling
into the slots as shown, and then
install the screws.
2. Place the floorboard mats in the
original position.
ECA00067
cCTake care not to damage the tabs
on the cowling when removing and
or installing it.11. Tab (×10)
5SJ-28199-E0 1/24/02 6:14 PM Page 57

6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
62. Remove the screws.
2 1
1
1. Screw (×4)
2. Cowling B
To install the cowling1. Insert the tabs on the cowling
into the slots as shown, and then
install the screws.
2. Place the floorboard mats in the
original position.
ECA00067
cCTake care not to damage the tabs
on the cowling when removing and
or installing it.
1
1. Tab (×10)
3. Pull the cowling down slightly,
and then pull it outward as
shown.
5SJ-28199-E0 1/24/02 6:14 PM Page 58

6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03617
Cowling C
To remove the cowling1. Remove the cowling screws.
1
1. Screw (×2)
2. Push the cowling in lightly, and
then pull it back as shown.
ECA00067
cCTake care not to damage the tabs
on the cowling when removing and
or installing it.aaa. Push.
5SJ-28199-E0 1/24/02 6:14 PM Page 59

6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
6To install the cowling
1. Insert the tabs on the cowling
into the slots as shown, and then
push the cowling in until it snaps
into place.
2. Install the cowling screws.
1
2
1. Tab (×4)
2. Slot (×4)
EAU03628
Panel A
To remove the panelRemove the bolts, and then pull the
panel out as shown.
1
2
1. Bolt (×2)
2. Panel A
5SJ-28199-E0 1/24/02 6:14 PM Page 60

6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
6 To install the panel
Place the panel in the original posi-
tion, and then install the bolts.
1
1
1. Tab (×4)
To remove the spark plug
1. Remove cowling B. (See page
6-8 for cowling removal and
installation procedures.)
2. Remove the spark plug cap.
1
1. Spark plug cap
EAU03620
Checking the spark plugSpark plug, checkingThe spark plug is an important
engine component, which is easy to
check. Since heat and deposits will
cause any spark plug to slowly erode,
the spark plug should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plug can reveal the condition of
the engine.
5SJ-28199-E0 1/24/02 6:14 PM Page 61